Load carrier system

ABSTRACT

A strap for securing cargo on a vehicle includes a strap and a buckle. The buckle has a releasable strap gripping device, and a cushioning material at least partially surrounding the buckle without obstructing accessibility to the gripping device.

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. Provisional PatentApplication Serial No. 60/186,870 filed Mar. 3, 2000 titled “LoadCarrier System,” which is hereby incorporated by reference.

FIELD OF THE INVENTION

[0002] The present invention relates to buckles and more particularly tobuckles used with straps to secure loads to vehicles.

BACKGROUND OF THE INVENTION

[0003] Loads are often secured to vehicles by straps that use a buckleto allow the length of the strap to be adjusted. Load carrier straps areoften used to secure heavy loads. The buckles must be sturdy and capableof reliably gripping a strap under high tension. Thus, buckles aretypically made of metal which creates a risk of damaging the finish of avehicle on which the strap is used. Metal buckles may also damage thefinish on the load being secured by the strap.

[0004] U.S. Pat. No. 6,023,821 discloses a buckle cover adapted to slideover a buckle for protecting adjacent objects. Unfortunately, this coverinterferes with normal use or adjustment of the buckle. The cover mustbe slid onto and off of the buckle with each use and is thereforecumbersome to use. The cover is also subject to being dislodged orinadvertently left off, leaving the metal buckle exposed. In addition,the cover is rather bulky and unstylish in appearance.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005]FIG. 1 is an isometric view of a buckle constructed according tothe present invention.

[0006]FIG. 2 is an isometric view of the structural components of abuckle constructed according to the present invention.

[0007]FIG. 3 is a cross-sectional view of the structural components ofFIG. 2.

[0008]FIG. 4 is a bottom view of the buckle of FIG. 1.

[0009]FIG. 5 is an isometric view of an alternative buckle according tothe present invention.

[0010]FIG. 6 is an isometric view of a portion of the buckle of FIG. 5.

[0011]FIG. 7 is a top view of a cam portion of the buckle of FIG. 5.

[0012]FIG. 8 is an isometric view of the structural portion of the camof FIG. 7.

[0013]FIG. 9 is a cross-sectional view of the cam of FIG. 7.

[0014]FIG. 10 is a cross-sectional view of the buckle of FIG. 5.

[0015]FIG. 11 is an isometric view of an alternative buckle according tothe present invention.

[0016]FIG. 12 is bottom view of the buckle of Fig. 11.

[0017]FIG. 13 is an isometric view of an alternative buckle according tothe present invention.

[0018]FIG. 14 is a bottom view of the buckle of FIG. 13.

DETAILED DESCRIPTION

[0019] The invention provides strap and buckling devices that combinerigid high-strength materials with elastomeric compressible materials inrugged, sturdy designs that are easy to use without damaging the surfaceof a vehicle or cargo carried on the vehicle.

[0020] A buckle constructed according to the present invention isdepicted generally at 10 in FIG. 1. Buckle 10 includes a metal frame 12and a metal cam 14, as shown in FIGS. 2 and 3. Buckle 10 includes sideplates 16, 18 and front and rear cross-members 20, 22. Cross-members 20,22 support side plates 16, 18 in a spaced-apart rigid relationship toeach other. Each side member includes at least one bore 24 through whicha cam pivot pin 26 fits. The cam pivot pin also passes through a bore 28in cam 14 to pivotally hold the cam in place relative to the side platesand front cross-member.

[0021] A spring 30 biases a front face 32 of cam 14 against frontcross-member 26. Cam 14 includes lever portion 34 opposite the frontface that a user depresses to move the front face away from cross-member26. Cross-member 26 includes serrations 36 that cooperate with teeth 38formed on front face 32 to grip strap 40. When the lever portion isdepressed, the strap is free to move between the cam and the frame. Whenthe lever is released, any tension on the strap in a first direction 42pulls the front face toward the cross-member, thereby firmly pinchingthe strap and preventing movement. Tension on the strap in the otherdirection 44 pulls the cam face away from the cross-member, allowing thestrap to be tightened, as shown in FIG. 3.

[0022] A bumper, protector or cushion 50 is formed on each side plate16, 18. The cushion is typically affixed to the side by overmolding. Thecushion is typically made of a flexible or resilient material, forexample TPE, that is soft enough to avoid damaging the surface of avehicle or cargo being carried by the vehicle. As shown in FIG. 4, pivotpin 26 includes an enlarged portion head 52 at each end. Heads 52 helpto mechanically retain the cushions on the frame of the buckle. Thecushions may be interconnected by a bridge or web portion 54, whichfurther stabilizes the cushions on the buckle. When utilizing somethermoplastic elastomer materials that do not have direct adhesion tometal parts, it is generally necessary to provide for a mechanicalinterconnection between the elastomer and the frame.

[0023] It should be noted that the cushions extend sufficiently abovethe side plates of the buckle to shield the cam lever from hitting anadjacent surface such as the surface of a vehicle or load. Although thecushion may not extend around the front or back of the frame, itprojects outward sufficiently from the side plates to shieldcross-members and other metal parts of the buckle from contact with thevehicle. The cushion is preferably thick and resilient enough to absorbimpacts of the buckle on a vehicle without denting or damaging thesurface of the vehicle. The cushions are typically formed of athermoplastic elastomer material, for example, TPE.

[0024] FIGS. 5-10 show an alternate buckle 100 according to the presentinvention. Buckle 100 includes structural components similar to those ofbuckle 10. However, as shown best in FIGS. 6 and 10, side plates 16, 18include auxiliary plates 102, 104, respectively. The auxiliary platesare mounted to the side plates on pillars 106, 108, respectively.Preferably, the frame includes both side plates and auxiliary platesmolded as a single unit. Cushions 120 are then overmolded onto theframe.

[0025] Cam 14 includes a cushion 60 disposed over the lever portion.Cushion 60 includes a depression 62 that provides a comfortable locationfor a user to place their finger to operate the cam. In instances wherethe cam lever projects beyond the edges of the side plates and or sideplate cushions, the cam cushion serves to provide additional protectionagainst damage to the vehicle finish.

[0026] Another buckle constructed according to the present invention isshown in FIG. 11 at 200. Buckle 200 incorporates structural componentssimilar to buckle 10. However, side plates 16, 18 on buckle 200 areformed with mushroom-shaped retainers 202 at the front and rear. Theretainers provide a mechanical grip for cushions 50. In addition oralternatively, side plates 16, 18 may include one or more holes 204, 206that allow a small amount 208, 210 of cushion material to flow throughand form a mechanical connection to the side plate.

[0027]FIGS. 13 and 14 illustrate another buckle constructed according tothe present invention at 300. Buckle 300 incorporates a structuralmember similar to buckle 10. The main difference is that cushions 50 onbuckle 300 are formed separately and attached to the structural memberwith rivets 302, 304, which pass through the front and rearcross-members. The cushions may also be connected by a piece ofelastomer or web portion 54 as with buckle 10.

[0028] The various buckles as described herein are useful for attachingloads to vehicles, particularly to roof racks and rear mounted racks.One example of a roof-mounted device that is suitable for use with thedisclosed buckles is described in U.S. patent application Ser. No.09/280,504, which is incorporated herein by reference.

[0029] It is believed that the disclosure set forth above encompassesmultiple distinct inventions with independent utility. While each ofthese inventions has been disclosed in its preferred form, the specificembodiments thereof as disclosed and illustrated herein are not to beconsidered in a limiting sense as numerous variations are possible. Thesubject matter of the inventions includes all novel and non-obviouscombinations and subcombinations of the various elements, features,functions and/or properties disclosed herein. Similarly, where theclaims recite “a” or “a first” element or the equivalent thereof, suchclaims should be understood to include incorporation of one or more suchelements, neither requiring nor excluding two or more such elements.

We claim:
 1. A strap fastener comprising a buckle including two rigidlateral supports, a gripping mechanism secured between the supports, andeach support having an elastomeric cushion member that at leastpartially encases the support and prevents the support from contacting asurface adjacent the fastener without obstructing accessibility to thegripping mechanism.
 2. The fastener of claim 1 , wherein the grippingmechanism includes a pivot pin spanning the supports, and aspring-biased cam lever that pivots around the pivot pin betweengripping and non-gripping positions.
 3. The fastener of claim 1 ,wherein the lateral supports are connected by at least two crossmembers.
 4. The fastener of claim 1 , wherein each lateral supportincludes a plate member.
 5. The fastener of claim 1 , wherein thelateral supports are connected by at least one cross member, the crossmember having two ends, each end extending through a bore in one of thelateral supports, each end of the cross member having an enlarged headportion securing the cross member and the cushion member to therespective support.
 6. The fastener of claim 5 , wherein the enlargedhead portions are rivets.
 7. The fastener of claim 5 , wherein eachcushion member is molded over an enlarged head portion of one of thecross members.
 8. The fastener of claim 5 , wherein the cushion membershave concavities for receiving the head portions of the cross member. 9.The fastener of claim 1 , wherein lateral supports are connected by atleast two cross members, each cross member having two ends, each endextending through a bore in one of the lateral supports, each end ofeach cross member having an enlarged head portion securing the crossmember in the lateral support so that each lateral support has at leasttwo head portions protruding from an external side of the support. 10.The fastener of claim 9 , wherein each cushion member is molded over atleast enlarged head portion on the external side of its respectivelateral support.
 11. The fastener of claim 9 , wherein the cushionmembers have concavities for receiving the head portions of the crossmembers on the external side of its respective lateral support.
 12. Thefastener of claim 1 , wherein the cushion members have a height thatprevents the gripping mechanism from contacting an adjacent surfaceduring normal operation of the gripping mechanism.
 13. The fastener ofclaim 1 , wherein the gripping mechanism includes a cam lever thatpivots around a pivot pin spanning the lateral supports.
 14. Thefastener of claim 13 , wherein the cam lever has an elastomer-coveredend portion.
 15. The fastener of claim 13 , wherein the cam lever has afront face with teeth for gripping a strap.
 16. The fastener of claim 15, wherein the buckle has a front cross member with teeth that cooperatewith the teeth on the front face of the cam lever to bite a strap. 17.The fastener of claim 15 , wherein the cam lever is spring biased towardengaging the strap.
 18. A strap fastener comprising a buckle having apair of rigid side supports connected by at least one cross member and apivot pin, and a spring-biased cam lever that pivots around the pivotpin between gripping and non-gripping positions, and each side supporthaving a cushion member over-molded on the side support.
 19. Thefastener of claim 18 , wherein each side support includes a plate. 20.The fastener of claim 18 , wherein the cross member has two ends, eachend extending through a bore in one of the side supports, each end ofthe cross member having an enlarged head portion securing the crossmember to the side support.
 21. The fastener of claim 18 , wherein thecushion members are connected by a bridge portion.
 22. The fastener ofclaim 18 , wherein the cushion members prevent rigid portions of thebuckle from contacting an adjacent surface without obstructing easymanipulative access to the cam lever.
 23. The fastener of claim 18 ,wherein the cam lever has an elastomer-covered end portion.
 24. Thefastener of claim 18 , wherein the cam lever has a front face with teethfor gripping the strap.
 25. The fastener of claim 24 , wherein thebuckle has a front cross member with teeth that cooperate with the teethon the front face of the cam lever to bite a strap.
 26. The fastener ofclaim 18 , wherein each side support has an auxiliary plate member, therespective cushion member being molded over the auxiliary plate member.27. A strap fastener comprising a buckle having a pair of rigid sidesupports connected by at least two cross members, each side supporthaving an auxiliary plate structure, and an elastomeric cushion membermolded over the plate structure so that the rigid side supports areprevented from contacting an adjacent contact surface.
 28. The fastenerof claim 27 , wherein each side support includes a plate.
 29. Thefastener of clam 27, wherein the cushion members are connected by abridge portion.
 30. The fastener of claim 27 , wherein the buckleincludes a gripping mechanism having a pivot pin, and a spring-biasedcam lever that pivots around the pivot pin between gripping andnon-gripping positions.
 31. The fastener of claim 27 , wherein eachcross member has two ends, each end extending through a bore in one ofthe side supports, each end of the cross member having an enlarged headportion securing the cross member in the side support so that each sidesupport has at least two head portions protruding from an external sideof the support.
 32. The fastener of claim 31 , wherein the enlarged headportions are rivets.
 33. The fastener of claim 31 , wherein each cushionmember is molded over at least one enlarged head portion on the externalside of its respective side support.
 34. The fastener of claim 31 ,wherein the cushion members have concavities for receiving the headportions of the cross members.
 35. The fastener of claim 30 , whereinthe cushion members have a height that prevents the gripping mechanismfrom contacting an adjacent surface during normal operation of thegripping mechanism.
 36. A strap fastener comprising a buckle having apair of rigid side members, and a strap gripping mechanism between theside plates, each side plate having an over-molded cushion that preventsthe side plates and gripping mechanism from contacting an adjacentsurface.
 37. The fastener of claim 36 , wherein the cushions areconnected by a bridge portion.
 38. The fastener of claim 36 , whereinthe gripping mechanism includes a pivot pin, and a spring-biased camlever that pivots around the pivot pin between gripping and non-grippingpositions.
 39. The fastener of claim 36 wherein the side members areconnected by at least two cross members.
 40. The fastener of claim 38 ,wherein the cam lever has an elastomer-covered end portion.
 41. Thefastener of claim 38 , wherein the cam lever has a front face with teethfor gripping a strap.
 42. The fastener of claim 41 , wherein the bucklehas a front cross member with teeth that cooperate with the teeth on thefront face of the cam lever to bite a strap.
 43. A strap for securingcargo on a surface comprising a strap, a buckle including a releasablestrap gripping device, and over-molded lateral bumpers on opposite sidesof the gripping device.
 44. The strap of claim 43 , wherein the lateralbumpers have a height that prevents the gripping device from contactingan adjacent surface during normal gripping and releasing operation ofthe gripping device.
 45. The strap of claim 43 , wherein the grippingdevice is secured between lateral supports, the lateral supports beingconnected by a pair of cross members, each cross member having two ends,each end extending through a bore in one of the lateral supports, andeach end of the cross member having an enlarged head portion securingthe cross member in the lateral support so that each lateral support hasat least two head portions protruding from an external side of thesupport.
 46. The strap of claim 45 , wherein each bumper is molded overat least two enlarged head portions on the external side of itsrespective lateral support.
 47. The strap of claim 45 , wherein thebumpers have concavities for receiving the head portions of the crossmembers.
 48. The strap of claim 45 , wherein the gripping deviceincludes a pivot pin and a spring-biased cam lever that pivots aroundthe pivot pin between gripping and non-gripping positions.
 49. The strapof claim 48 , wherein the cam lever has a front face with teeth forgripping a strap.
 50. The strap of claim 49 , wherein the buckle has afront cross member with teeth that cooperate with the teeth on the frontface of the cam lever to bite a strap.
 51. A strap for securing cargo ona surface comprising a strap, a buckle including a releasablestrap-gripping device, and a cushion material at least partiallysurrounding the buckle without obstructing accessibility to the grippingdevice.
 52. A strap for securing cargo on a surface comprising a strap,a buckle including a pair of rigid side plate members, each side platemember having a perimeter edge and a cushion member extending beyond theperimeter edge.